Plug valve with improved flow capacity

ABSTRACT

An apparatus is provided that in some embodiments provide an improved plug valve having a plug with a curved cylindrical sealing surface and a substantially flat second surface. An inlet region of the housing has a constant cross-sectional flow area.

FIELD OF THE INVENTION

The present invention relates generally to the field of eccentric plug valves which may be used to control the flow of fluid in pipe systems.

BACKGROUND OF THE INVENTION

Eccentric plug valves have been available to industry for some time, and typically include a main body having an inlet port and outlet port and a plug mounted for rotation about a shaft, so that a plug face is eccentrically rotated to either close off or open flow through a valve seat area. Such valves are used, for example, in wastewater, mining, fresh water, and many other industrial and HVAC services.

The plug valves typically have a long service life and are known for their reliability. Many of the valves are sold for use in sludge and slurry services such as wastewater, ash, mining tailings, and other similar applications. Eccentric plug valves generally include two types: wherein the rotatable plug and mating seat is either cylindrical or spherical.

Cylindrical plugs are sometimes desirable and seal against a cylindrical seat around a seal seat area. When the valve is closed, a seal is created between the plug and a typically nickel seat. Oftentimes, the vavles have a restriction in their internal flow when open, because due to internal configuration the flow area may for example be only approximately 80% of the internal pipe diameter flow area for which the valve is connected. The plugs are normally elastomer faced for tight fluid shutoff and for abrasion and erosion resistance. Valves are often provided with a standard “face to face” length conforming to US and ISO standards for plug valves.

Eccentric plug valves are quite versatile. In most liquid service for example, it is recommended that the valve be installed with the nickel seat in the downstream location of the valve. In the case of suspended solid service such as slurry and sludge, it is sometimes recommended that the valve be installed with the seat upstream and/or with shaft axis horizontal, such that the plug is raised above the pipe centerline when the valve is open. This assists with keeping the plug and bearings away from accumulated settled grit, fines and other debris that can accumulate in the bottom of a valve body.

While the above valve designs are quite useful, available industrial plug valves valve designs, such as an example shown in FIG. 11, have typically had a restriction to the fluid flow that occurs due to restrictions in the flow area configuration, for example, the flow area is approximately 80% of the pipe area in some designs.

One solution to this has been to install an oversized valve, so that the port area will effectively be 100% of pipe inside flow area. However, this has the disadvantage that the oversized valve is heavy, expensive, and may require a larger actuator which may also be more expensive, as opposed to a more compact unit. Further, the oversized valves will be made with the smaller flange but will have an increased face to face area. This reduces interchangeability of the valves.

Another disadvantage of the known plug valves is that where they are installed in sludge or slurry service, the intersection of the cylindrically body wall with a point of a flat flange can sometimes form a partial wedge shaped dam that allows sediment and other debris to accumulate in the lower section of the valve as noted above.

Accordingly, it would be desirable to have an improved plug valve with cylindrical seating that can at least to some degree enhance fluid flow and/or ameliorate the buildup effects of suspended solids use.

SUMMARY OF THE INVENTION

The foregoing needs are met, to a great extent, by the present invention, wherein in one aspect an apparatus is provided that in some embodiments provides an improved plug valve with cylindrical seating that can at least to some degree enhance fluid flow and/or ameliorate the effect of suspended solids use.

In one aspect, some embodiments of the invention provide a valve apparatus, comprising, a valve body having an inlet port and an outlet port having a seat opening; and a plug rotatably mounted in the valve body and having a cylindrically curved sealing face and a substantially planar second face opposite to the curved sealing face.

In one aspect, some embodiments of the invention provide a valve apparatus, comprising, a valve body having an inlet port and an outlet port having a seat opening; and a plug valve rotatably mounted in the valve's body having a cylindrically curved sealing face wherein the inlet part comprises an entry region having a change in outline shape but no change in total area.

In one aspect, some embodiments of the invention provide valve apparatus, comprising, housing means having an inlet port and an outlet port having a seat opening; and sealing means rotatably mounted in the housing means having a cylindrically curved sealing face and a substantially planar second face opposite to the curved sealing face.

In one aspect, some embodiments of the invention provide a valve apparatus, comprising, housing means having an inlet port and an outlet port having a seat opening; and sealing means mounted in the housing means having a cylindrically curved sealing face, wherein the inlet part comprises an entry region having a change in outline shape but no change in total area.

In one aspect, some embodiments of the invention provide a method of improving flow is a valve assembly housing a valve body having an inlet port and an outlet port having a seat opening, comprising, rotating a plug mounted in the valve body having a cylindrically curved sealing face and a substantially planar second face opposite to the curved sealing face, wherein the plug is moveable between an open position and a closed position, so that in the open position the second face of the plug is aligned with a vertical corner surface located towards the inlet port and a substantially vertical seat edge located towards the outlet port.

There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein maybe better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a plug valve according to a preferred embodiment of the invention, taken through line 1-1 in FIG. 2.

FIG. 2 is a top view of a plug valve according to a preferred embodiment of the invention.

FIG. 3 is a side view of a valve plug used in the embodiment of FIG. 1.

FIG. 4 is a cross-sectional view taking through line 4-4 in FIG. 3.

FIG. 5 is a cut away perspective view of an embodiment of the plug valve.

FIG. 6 is a cut away top view of the valve of FIG. 5 shown in an open position

FIG. 7 is a cut away top view of the valve of FIG. 5 shown in a closed position.

FIG. 8 is a perspective view of a valve body used in the embodiment of FIG. 1.

FIG. 9 is a cross-sectional view of the valve body shown FIG. 8, taken through line 9-9.

FIG. 10 is a symmetric cross-sectional diagram showing a flow path of fluid through a valve according to a preferred embodiment with the valve in an open position.

FIG. 11 is a symmetric cross-sectional diagram showing a flow path of fluid through a prior art valve arrangement with this valve in an open position.

FIG. 12 is a diagram similar to FIG. 10, but showing the valve installed in a reverse orientation.

FIG. 13 is a diagram similar to FIG. 11, but showing the valve installed in a reverse orientation

DETAILED DESCRIPTION

The present invention in some embodiments provides an improved plug valve and flow control method with cylindrical seating that can at least to some degree enhance fluid flow and/or ameliorate the effect of suspended solids use. A preferred embodiment will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout.

FIG. 1 illustrates a plug valve 10 according to a preferred embodiment of the invention, including a body 12, a bonnet 14, and a valve plug 16. The valve plug 16 is rotatably mounted within the chamber formed by the housing 12 and the bonnet 14 and is moveable between open and closed positions as will be described in more detail below. FIG. 2 is a top view of the arrangement shown in FIG. 1 and further illustrates the housing 12, bonnet 14 and a shaft portion of the valve plug 16.

Turning now to FIGS. 3 and 4 in particular, the valve plug 16 is illustrated to have the shaft 18, a plug region 20 having a back face 22 and a front sealing face 24, and upper and lower connecting regions 26 and 28. A lower shaft 30 is also mounted by a bushing for rotation with respect to the body 12 and the shaft 18 is mounted for rotation with respect to the bonnet 14. Thus, the plug 16 is mounted for rotation about an axis of rotation that is a longitudinal axis through shafts 18 and 30. Although the preferred embodiment is shown with a unitary plug having integral top and bottom shafts, in other embodiments a separate top and/or bottom shaft can be attached to the shaft, for example by being pinned t o the plug. The direction parallel to the axis of rotation is referred to herein as “vertical” in order to provide a useful reference coordinate herein. Other directions and orientations will be described as vertical herein, meaning they are parallel to this axis. However, it is to be understood that the valve may actually be installed in any orientation, including an orientation where the rotational axis is horizontal relative to the direction of gravity, and in such case, the reference to vertical herein refers to parallelism with this rotational axis, and not necessarily to the direction of gravity. Also, although FIGS. 1-10 show flow in one direction from an inlet to outlet, it will be appreciated that in some installations the orientation of the valve are reversed so that the “inlet” and “outlet” sides are reversed. This type of installation, for example of which is shown in FIG. 12, is typically intended for installations high in sludge and/or particulates.

Turning to FIG. 5, additional features of the valve plug 16 and body 12 are illustrated. FIG. 5 illustrates that the rear face 22 of the valve plug 16 has a substantially flat or planar profile as shown, while the outer face 24 has a cylindrical profile shape. The body 12 includes an inlet flange 30 and an outlet flange 32. The inlet flange 30 leads to an inlet flow path area 34 which transitions from a circular opening 36 to a slightly narrower curved side entry transition region leading to a rear edge 40, and opposite arranged to a tapered side 41 having a relatively straight vertical corner inlet edge 42.

When the valve 10 is in the open position shown in FIG. 5, the flat surface 22 of the valve plug 16 is substantially aligned with edge 42. A cylindrical rectangular valve seat area 44 is provided against which the outer surface 44 of the valve plug 16 engages when the valve 10 is in a closed position, as will be described in further detail below. Behind the seat 44, the flow path generally expands due to diverging tapered surfaces 46 leading to the end of the outlet flange 32.

The valve 10 is shown in an open position in FIG. 6. The body 14 includes the front flange 30, and the curved sidewall 38 leading to a rear side edge 40. The other rear vertical side edge 42 is also shown and it is in substantial alignment with the rear surface 22 of the plug 16. Also shown is the outer sealing face 24 of the plug 16 and the overall seat 44, as well as diverging tapered surfaces 46.

It will be appreciated that the generally cylindrical rectangular outline of the seat 44 has a vertical left edge 45 that is generally aligned with and does not project beyond the plane formed by the vertical inside surface 24 of the plug 16. Thus, FIG. 6 illustrates a generally planar relationship between the vertical inlet edge 42, the vertical seat edge 45, and the rear or inside face 22 of the plug 28.

As will be discussed in more detail below, it will be appreciated that this provides a smooth and uninterrupted flow boundary along the plane shown in the left side of the flow area of the arrangement of FIG. 6. Further, on the regions to the right side of FIG. 6, the relatively straight vertical edge 40 and its smooth transition contour at the cylindrical gradual transition entry region 38 will provide for a fairly straight and wide flow path.

FIG. 7 shows the valve 10 in a closed position. The outer surface 24 of the valve plug 16 is in contact with the seat 44 to perform the intended shutoff of fluid flow.

FIGS. 8 and 9 are perspective and cross sectional views of the valve body 12. In FIG. 8, inside of the inlet flange 30 can be seen the vertical inlet edge 42 as well as the more rounded extended inlet edge 40 defined by the gradual transition region 38. Near the outlet flange 32 can be seen the vertical edges of the seat 44 and the transition region 46.

The cross sectional view of FIG. 9 further shows on the inlet side, the rectangular cylindrical outline of the seat 44 and its left edge 45, as well as the circular outlet region 46.

FIG. 10 is a simplified schematic flow diagram which illustrates some of the benefits achieved by various aspects of various embodiments of the present invention. For example, the flat surface 22 of the rear of the valve plug 16 and its alignment with the vertical flow boundary edge 42 and the vertical edge 45 of the seat 44 provide a smooth fluid flow through the valves 10. Further, the relatively straight vertical edge 40 and the smooth entry region 38 also permits an uninterrupted smooth fluid flow at that area.

While it may appear from the cross section of FIG. 10 that the volumetric flow area at the front inlet face of the flange 30 is larger than the volumetric flow area taken at the vertical edge 40, this does not have to be the case because during the transition from the front opening 36 to the vertical edge 40, a change in the vertical height the flow cross-sectional area can also be occurring. Therefore, the two dimensional flow area at front face edge 36 and at the vertical edge 40 can be made the same as each other, and further can be made 100% the inner diameter area of the pipe to which the valve is connected if that is so desired. Also, the two dimensional flow area at the seat 44 can be made equal to the inner diameter area of the pipe

FIG. 10 also contrasts this particular embodiment of the invention with a prior art arrangement as shown in FIG. 11. Some differences that are illustrated include, for example, that a constricting wedge area 70 shown in FIG. 11 is not present in FIG. 10, which instead shows a smooth entry region 38. Also shown in FIG. 11 is a convex rear surface 72 of the plug, which can undesirably restrict the free flow area compared to the flar rear surface 22 of this embodiment of FIG. 10.

FIG. 12 shows the valve 10 with the flow direction reversed and in a horizontal position. This installation may be preferred for example in applications high in sludge and/or particulates. It will be seen that the smooth transition region 38 allows sediment to be carried out and not form a dam as would occur at location 99 of the prior art shown in FIG. 13 (wherein the valve of FIG. 11 installed upside down and backwards).

The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. 

1. A valve apparatus, comprising: a valve body having an inlet port and an outlet port having a seat opening; and a plug rotatably mounted in the valve body and having a cylindrically curved sealing face and a substantially planar second face opposite to the curved sealing face.
 2. The apparatus according to claim 1, wherein the valve body comprises a first body component a second body component detachably mounted to the first body component to form a chamber within which the plug is rotatable.
 3. The apparatus according to claim 2, wherein the first body component comprises a body having the seat opening and the second body component comprises a bonnet.
 4. The apparatus according to claim 1, wherein the inlet port comprises an entry region having a change in outline shape but no change in total area.
 5. The apparatus according to claim 1, wherein the valve body has a height, and a cross section taken at an intermediate portion of the height perpendicular to the axis of rotation of the plug has one tapered sidewall and one straight sidewall.
 6. The apparatus according to claim 1, wherein the plug is moveable between an open position and a closed position, and wherein in the open position the second face of the plug is aligned with both of a substantially vertical corner surface located towards the inlet port and a substantially vertical seat edge located towards the outlet port.
 7. The apparatus according to claim 4, wherein the valve is connected to a pipe having a pipe flow volume area, and a total volume area of the entry region is substantially equal to the pipe flow area.
 8. The valve apparatus, comprising: a valve body having an inlet port and an outlet port having a seat opening; and a plug valve rotatably mounted in the valve body having a cylindrically curved sealing face wherein the inlet port comprises an entry region having a change in outline shape but no change in total area.
 9. The valve apparatus according to claim 8, wherein the valve is connected to a pipe having a pipe flow volume area, and a total area of the entry region is substantially equal to the pipe flow area.
 10. A valve apparatus, comprising: housing means having an inlet port and an outlet port having a seat opening; and sealing means rotatably mounted in the housing means having a cylindrically curved sealing face and a substantially planar second face opposite to the curved sealing face.
 11. The apparatus according to claim 10, wherein the housing means comprises a first body component a second body component detachably mounted to the first body component to form a chamber within which the sealing means is rotatable.
 12. The apparatus according to claim 11, wherein the first body component comprises a body having the seat opening and the second body component comprises a bonnet.
 13. The apparatus according to claim 10, wherein the inlet port comprises an entry region having a change in outline shape but no change in total area.
 14. The apparatus according to claim 10, wherein the housing means has a height, and a cross section taken at an intermediate portion of the height perpendicular to the axis of rotation of the plug has one tapered sidewall and one straight sidewall.
 15. The apparatus according to claim 10, wherein the sealing means is moveable between an open position and a closed position, and wherein in the open position the second face of the plug is aligned with both of a substantially vertical corner surface located towards the inlet port and a substantially vertical seat edge generally located towards the outlet port.
 16. The valve apparatus according to claim 10, wherein the valve is connected to a pipe having a pipe flow volume area, and a total area of the entry region is substantially equal to the pipe flow area.
 17. A valve apparatus, comprising: housing means having an inlet port and an outlet port having a seat opening; and sealing means mounted in the housing means having a cylindrically curved sealing face, wherein the inlet port comprises an entry region having a change in outline shape but no change in total area.
 18. The valve apparatus according to claim 17, wherein the valve is connected to a pipe having a pipe flow volume area, and a total volume area of the entry region is substantially equal to the pipe flow area.
 19. A method of improving flow is a valve assembly including a valve body having an inlet port and an outlet port having a seat opening, comprising: rotating a plug mounted in the valve body having a cylindrically curved sealing face and a substantially planar second face opposite to the curved sealing face, wherein the plug is moveable between an open position and a closed position, so that in the open position the second face of the plug is aligned with a substantially vertical corner surface located towards the inlet port and a substantially vertical seat edge located towards the outlet port.
 20. The apparatus according to claim 19, wherein the inlet port comprises a region having a change in outline shape but no change in total area. 